Foaming mesh extrusion and method for making same

Abstract

An extruded mesh that is activatable at predetermined temperatures for expansion when desired and a method for manufacturing same. The process includes providing an extrusion tool assembly where the flow of the polymer is interrupted intermittently to allow for the gaps in the mesh in the extrudate to assist with expansion.

What is claimed is: 
     
         1 . An extruded mesh, comprising:
 at least one mesh member expanded in at least a horizontal and vertical direction, said mesh member formed of a predetermined expandable material operable for predetermined desired expansion in at least the horizontal and vertical directions at a predetermined temperature; and   a plurality of gaps formed in the expanded mesh member in a predetermined repeating pattern.   
     
     
         2 . The extruded mesh of  claim 1 , wherein said predetermined expandable material is an activatable material including at least one epoxy, at least one elastomer, at least one blowing agent, at least one curing agent, and, optionally, at least one filler. 
     
     
         3 . The extruded mesh of  claim 1 , wherein the plurality of gaps are operable spaced to assist with the expansion of the at least one mesh member in the horizontal and vertical directions. 
     
     
         4 . The extruded mesh of  claim 1 , wherein the plurality of gaps are arranged in a plurality of parallel rows. 
     
     
         5 . The extruded mesh of  claim 1 , wherein the plurality of gaps are aligned in a plurality of parallel columns. 
     
     
         6 . The extruded mesh of  claim 1 , wherein the plurality of gaps are slots through the at least one mesh member. 
     
     
         7 . The extruded mesh of  claim 1 , wherein the plurality of gaps are each about 0.25 to 1 inches long. 
     
     
         8 . The extruded mesh of  claim 1 , wherein the plurality of gaps are each at least about 0.2 mm wide. 
     
     
         9 . The extruded mesh of  claim 1 , further comprising at least one fastener affixed in the extruded mesh. 
     
     
         10 . The extruded mesh of  claim 1 , further comprising at least one non-expanded mesh member integrally formed with or operably affixed to at least one of the at least one mesh member. 
     
     
         11 . The extruded mesh of  claim 10 , further comprising at least one fastener affixed in the at least one non-expanded mesh member. 
     
     
         12 . The extruded mesh of  claim 1 , wherein the at least one non-expanded mesh member comprises a plurality of expanded integral horizontal rows and vertical columns bounding the plurality of gaps. 
     
     
         13 . The extruded mesh of  claim 1 , wherein the expandable material is activated to expand at a temperature of about at least 300° F. 
     
     
         14 . The extruded mesh of  claim 1 , wherein the expandable material is extrudable at a temperature in the range of about ambient temperature to below 300° F. 
     
     
         15 . The extruded mesh of  claim 1 , wherein the expandable material expands to provide a predetermined thickness of the at least one mesh member in the range of about 0.25 to 1 inches. 
     
     
         16 . The extruded mesh of  claim 1 , wherein the expandable material is operable for operably affixing the at least one mesh member to an automotive part and expansion of the at least one mesh member in a paint oven at predetermined temperatures. 
     
     
         17 . An activatable foaming mesh extrusion, comprising:
 at least one mesh member formed of an activatable material comprising one or more of at least one epoxy, at least one elastomer or reaction product, at least one blowing agent, at least one curing agent, and optionally, at least one filler, said at least one mesh member expanded a predetermined amount by said activatable material;   a plurality of vertical and horizontal rows formed in the expandable mesh extrudate; and   a plurality of gaps operable to assist with predetermined expansion of the expandable mesh extrudate in at least the horizontal and/or vertical directions.   
     
     
         18 . A method for making an expandable mesh, comprising:
 providing an expandable material operable for extrusion at a predetermined temperature and operable for expansion at a higher predetermined temperature than the predetermined extrusion temperature, said expandable material comprising one or more of at least one epoxy, at least one elastomer or reaction product, at least one blowing agent, at least one curing agent, and optionally, at least one filler;   providing an extrusion tool assembly including at least one mandrel mechanism operable to move in/out of a flow of polymer material moving at a predetermined speed and pressure inside an extrusion die, said in/out movement operable to form a plurality of gaps in a mesh member;   providing at least one motion mechanism operably coupled to the at least one mandrel mechanism to provide said movement of the at least one mandrel mechanism in/out of the polymer flow at a predetermined speed of motion;   applying a flow of the polymer material to the at least one extrusion tool assembly and moving the at least one mandrel at the predetermined speed of motion in/out of the polymer flow, wherein the at least one mandrel intermittently blocks the polymer material flow to form the plurality of gaps;   extruding the polymer material through at least one die plate forming the extrudate including the mesh member with the plurality of gaps;   operably activating the mesh member to expand the mesh member a predetermined amount.   
     
     
         19 . The method of  claim 18 , wherein the motion mechanism converts rotary movement to linear movement to cause said at least one mandrel to move in a longitudinal direction with respect to the polymer material flow. 
     
     
         20 . The method of  claim 18 , wherein the motion mechanism includes an eccentric cam to operably convert rotary movement of the eccentric cam to linear movement of the at least one mandrel. 
     
     
         21 . The method of  claim 18 , wherein the mesh member is activated by heating the mesh member to about at least 300° F. to expand the mesh member to predetermined dimensions.